Electrical winding construction



June 14, 1960 w. T. SUTTON, JR 2,941,172 ELECTRICAL WINDING CONSTRUCTION Filed Sept. 24, 1957 INVENTOR fife! TEA [Jun-0N JE'.

ATTO R N EY5 Walter T. Sutton,

Electronics, New Jersey Filed Sept. 24, 1957, Ser. No. 685,882 11 Claims. (Cl. 336-92) Jr., Lexington,

Ky., assignor to Essex Berkeley Heights,

N.J., a corporation of My invention relates to an improved electrical coil and transformer construction rendering the same particularly useful in the automatic assembly of such circuit components into circuit sub-assemblies, as into printed circuits. This application discloses improvements over and modifications of the various forms disclosed in copending Goldsmith application, Serial No. 626,175, filed December 4, 1956.

It is an object of the invention to provide an improved construction of the character indicated.

It is another object to provide an improved electricalcoil circuit element which can be fabricated at substantially reduced cost.

It is a specific object to achieve the above objects with a construction in which the ends of the wire of the coil or coils are themselves the mounting prongs, of strength adequate to provide the substantial mounting support for the circuit element.

It is in general an object to meet the above objects with an extremely rugged and simple device which can achieve or exceed the electrical performance of previous structures and which may be so rugged and permanent as to constitute a trouble-free component for the life of the circuit in which it is embodied.

Other objects and various further features of novelty and invention will be pointed out or will occur to those skilled in the art from a reading of the following specification, in conjunction with the accompanying drawings. In said drawings, which show, for illustrative purposes only, preferred forms of the invention:

Fig. 1 is an exploded view of essential components of a coil construction embodying my invention, and with the body portion shown partially in longitudinal section;

Fig. 2 is a longitudinal sectional view of a fully as sembled coil of Fig. 1;

Fig. 3 is a bottom-end view of the assembly ofFig. 2, showing the section 1-1 for Figs. 1 and 2;

Fig. 4 is an exploded view similar to Fig. l but illustrating a component of a transformer construction embodying the same principles; and

Figs. 5 and 6 are views similar to Fig. 2, but illustrating modifications.

Briefly stated, my invention contemplates application to the construction of coils, transformers, chokes, and the like, for use in electronic circuit assemblies as, for example, in the video amplifier of a television set. The invention features integral formation of the turns of the electrical coil with the mounting leads or prongs, and for this purpose, employs relatively heavy, stiff wire for the turns of the coil or coils. The assembly is made rugged and adaptable to receive an adjustably positioned magnetic core by securing the same with a plastic bonding agent, such as an epoxy resin. Various forms will be shown and described.

In Figs. 1, 2 and 3 of the drawings, my invention is shown in application to a coil assembly in which the coil 10 is developed on or received upon and concentrically supported by a tubular coil-form portion or stem 11 of States Patent Ofitice .13 when assembled 2,541,172 Patented June 14, 1960 a plastic body member 12. The body member 12 includes at one end thereof an integral radially outwardly extending flange 13 which is shown to serve as an axially locating support for the adjacent end of the coil 10. The Winding 10 is developed from relatively heavy and stiff insulated wire, and is shown as a single layer of turns, the ends of which are so formed and trimmed as to project axially beyond the axial confines of the coil and so as to similarly project axially beyond the flange thereto. Heavy plastic-coated copper magnet wire or Copperweld (copper-sheathed steel wire) is well adapted to form the Winding means 10.

The wire from which the winding 10 is formed is preferably so rugged that the projecting ends 14-15 of the coil 10 may serve as the mounting pins for the finished structure, so that no soldering or other connection to separate mounting pins is necessary to integrate the circuit component into its ultimate chassis. For convenience in mounting, the leads 14-15 may be nail-pointed by employing conventional machinery, but I indicate my preference that the projecting ends 14- 15 shall be mercly dipped in a pool of solder and slowly raised so as to develop pointed solder ends 14-15', in the manner of a stalactite, the solder being further desirable for ultimate simpler permanent assembly into a printed circuit. The leads 1415 may project for different axial lengths, thereby providing unambiguous terminal identification. As indicated in Fig. 3, I prefer that lead-wire retaining sockets or recesses or openings 16 be provided in gularly spaced plurality about the base or flange 13 to receive and provide alignment support for the wires 14-15; four such recesses are shown for the case of the flange 13, anticipating that for certain situations the body member 1013 may be employed as the form on which two concentrically supported transformer windings are received, there being then one socket or opening 16 for each of the leads for the various transformer windings. Such a transformer will be more fully disclosed in connection with Fig. 4.

For unambiguous ultimate circuit orientation, I me for that the base or flange 13 be provided with a lobe 17 or other key means, whereby automatic-handling machinery may sense orientation and establish proper angular reference to the chassis to which the circuit components may be assembled. I also indicate my preferonce that plastic-bonding means such as an epoxy resin be employed to permanently secure the turns of the Winding 10 to each other and intimately to the coil form 11 and adjacent portions of the flange 13; for clarity, such bonding is not shown in the present drawings, but full potting is illustrated in said Goldsmith application, and partial potting is illustrated in pending Goldsmith application, Ser. No. 716,106, filed February 19, 1958.

In order to provide for adjustment of the electrical inductance of the coil 10, the bore 18 of the stem or coil form 11 may be ribbed or otherwise formed to readily accommodate the threads of a ferrite or the like core member 19, keyed at 19 for adjustment, all as described in said application, Serial No. 626,175. It will be appreciated that by positively locating the coil 19 by seating the same against the flange 13, I provide for maximum axial clearance between the inner end of coil 10 and the reduced end of the coil form 11; this means a substantial length of the coil form within which core member 19 may be accommodated with minimum coupling to coil 10, so that a maximum range of coupling adjustment is available.

The parts which have thus far been described may com prise a complete independently utilizable assembly, but] prefer that the assembly be encased, andhave therefore shown a cup-shaped housing member 20 for the purpose,

The housing member 20 comprises a generally cylindrical body portion or skirt 21 having means such as a radially inward flange 22 at one end for substantially closing said one end when assembled to the stem or coil-form merriber 11. The means for securing housing 20 to the body member 11 may simply be established by forming'the coil-form portion 11 initially with such axial length as to and I have shown the key means 17 of the base or flange '13 accurately located and received within the recess defined by the key 25 at the skirt of the housing 20.

As indicated generally above, the body member 12 and housing 20 are adapted to receive transformer windings,

namely, a winding in addition to the winding described in connection with Figs. 1 to 3. Such a transformer configuration is suggested in Fig. 4 wherein the parts are shown in exploded relation. Corresponding parts have been given the same reference numerals, and the winding 10 has been shown as the inner winding of the trans former. The only difference between the winding 10 shown in Fig. 4 and the winding 10 shown in Fig. 1 is that "the lead for one end thereof is formed with a slightly greater radial offset, or at least said lead 15' must be formed with such offset as to permit reception of the turns of the other winding 36 radially between the lead wire 15' and the body of the winding 16. The winding 30 is preferably also formed of the same insulated relatively stiff wire as the winding 10, and with leads 31-32 projecting integrally beyond one axial end at locations spaced angularly from each other and from the angular location of the leads 14-15, as for example to be received in the remaining available lead-locating recesses 16 in the base or flange 13.

It will be understood that, upon assembly, coil 10 will be concentrically supported on the coil form or stem 11 and that coil 30 will be concentrically supported by coil 10. Depending upon the relative axial length of the two windings 10-30, one or both of themmay be axially located against the flange 13, and preferably a plastic bonding 'compound, such as an epoxy resin, is employed to intimately secure the turns of both windings to each other in concentrically located relation and to the coil form and to the adjacent face of the flange 13. The same closure cap or housing 20 may be employed and may be secured to'the body member 12 in the manner discussed in connection with Figs. 1 to 3, in which case the bonding com.-

pound also preferably establishes a secure bond of the I coils and flange 13 to the skirt 21; this result may be achieved by sending a sufficient-heating current through one or both coils 10--30, to cause enough potting compound to flow into contact with skirt, and by thereafter cooling to establish a permanent bond. .In the case of Fig. 4, as with the case of Figs.'l to 3, the projecting lead ends 14-15 and 3132 are of such length compared with the weight and size of the completed assembly that theyprovide the substantial mounting support for the entire structure, and no additional parts or soldering connections are necessary to complete the assembly.

-The arrangement of Fig. 5 in all respects resembles that alreadydescribed for Figs. 1 to 3 and 4, except that the closure cap or housing 20' is secured to the body member 12 at the skirt end of the member 20', rather than at the flanged end 22 thereof. Thus, the skirt 21' may be radially inwardly deformed at 35 into permanent locating relation with adjacent parts of the flange 13 of body memher 12. This may complete the assembly, but, as indi- 4 tablishing a permanent bond of the turns to each other, as well as to the coil form and to the housing 25.

In the arrangement of Fig. 6, the body member 40 is a bobbin having a coil-form portion 41 with radially outwardly extending flanges 4243 at both axial ends thereof. The flange at 43 may be formed with wire-locating recesses 16, as described in Fig. 3; also, the winding 10 may be as described in Figs. 1 to 3, and the leads '14-15 received in the flange 43 as described in Figs. 1 to 3 for the flange 13. The employment of flanges 4243 at both ends of the body member 41 permits the use of simpler extruded tubular material for the housing or closure member 44, the same being shown as formed over at 45 into permanent retaining relation with the flange 42. This operation may or may not be necessary, depending upon whether the potting agent is caused to flow before or after assembly to the housing 44. I indicate my preference for completing the potting after assembly of the housing member 44, whereby potting material may flow into and establish intimate contact with the coil or coils, with the coil form 41, and with at least the lower end of the inner .wall 44 of the housing, so that all parts are permanently preferred forms shown, it will be understood that modifications may be made within the scope of the invention as described in the claims which follow.

I claim:

1. In combination, a flanged tubular coil-supporting body member, comprising an elongated tubular coil-form portion with a radially outwardly extending integral flange at one end, and an electrical winding comprising turns of relatively heavy and stiff wirederiving concentric support directly from the outer wall of said body of said coil form portion, the rim of said flange having openings to receive the wire of said winding, and the ends of said winding being straight and integrally formed with said winding to project through and derive alignment support from said openings and to project axially beyond the axial end of said body member, the stiffness and weight of said wire being such that the projecting ends of said winding provide essentially the full mounting support of said combination.

2. In combination, a flanged tubular coil-supporting body member, comprising an elongated tubular coil-form portion with a radially outwardly extending integral flange at one end, and an electrical winding comprising a single layer of turns of relatively heavy and stiff wire deriving concentric support directly from the outer wall of said body of said coil-form portion, the rim of said flange having openings to receive the wireof said winding, the ends of said winding being straight and integrally formed with said winding to project throughand derive alignment support from said openings and to project axially beyond the axial end of said body member, and plastic bonding means permanently securing the turns of said winding to said coil-form portion, the weight and stiffness of said wire being such that said projecting wire ends may provide the substantial mounting support for said combination.

3. In combination, a flanged tubular coil-supporting body. member, comprising an elongated tubular coilform portion with a radially outwardly extending flange at one end, and an electrical winding comprising turns of relatively heavy and stiff wire deriving concentricsupport directly from the outer wall of said body of said coil-form portion, the rim of said flange having openings to receive the wire of said winding, the ends of said winding being straight and integrally formed with said winding to project through and derive alignment support from said openings and to project axially beyond the axial end of said body member; a generally cup-shaped housing member defining a cylindrical outer wall, said housing member having means at one end thereof for engagement with said coil-form portion, and means at the other end for engagement with said flange; and means permanently securing said housing to said body member at one of said ends, the weight and stiffness of said wire being such that the projecting ends of said winding may provide essentially the full support of said combination.

4. The combination of claim 3, in which the axial length of said body member with respect to said housing is such that said coil-form portion projects axially beyond the corresponding end of said housing when initially assembled together, said projecting portion being permanently deformed into radially overlapping engagement with the adjacent portion of said housing.

5. The combination of claim 3, in which the axial length of said housing with respect to said body member is such that when initially assembled to each other, the end of said housing adjacent said flange projects axially therebeyond, said projecting portion of said housing being permanently inwardly deformed into radially overlapping retaining relation with said flange.

6. In combination, a plastic tubular coil-supporting body member defining a coil form, an electrical winding comprising a plurality of turns of relatively heavy and stiff wire deriving concentric support directly from the outer wall of the tubular body member, said body memher being formed at one end with an integral radially outwardly extending flange against which turns of said winding are axially located, the ends of said winding being straight and integrally formed with said winding to project axially beyond said axial end of said body member, said flange having guide openings supporting said winding ends in angularly spaced relation with respect to the coilform axis, the weight and stiffness of said wire being such that said projecting wire ends provide the substantial mounting support for said combination, and plastic bonding' means permanently fixing said winding to said body member.

7. In combination, a plastic tubular coil-supporting body member defining a coil form, an electrical winding comprising a plurality of turns of relatively heavy and stiff wire deriving concentric support directly from the outer wall of said tubular body member, said body member being formed at one end with an integral radially outwardly extending flange against which turns of said winding are axially located, said flange having angularly spaced openings for the ends of said winding, the ends of said winding being straight and integrally formed with said winding to project through the openings of said flange and axially beyond said axial end of said body member, the weight and stiffness of said wire being such that said projecting wire ends provide the substantial mounting support for said combination, plastic bonding means permanently fixing said winding to said body member, and a housing comprising a cup-shaped generally tubular member, including a generally cylindrical outer wall with an integral radially inwardly extending flange at one end thereof and engaging the coil-form portion of said tubular body member, the skirt of said housing at the other end thereof havi g means engaging the flanged end of said body member.

8. In combination, a plastic, tubular coil-supporting body member integrally formed at one end with a radially outwardly extending retaining flange, a first winding comprising a first plurality of turns of relatively heavy and stiff wire deriving concentric support directly from the outer wall of said body member, a second winding comprising a plurality of turns of relatively heavy and stiff Wire deriving concentric support from said first winding, the wire ends for said windings projecting straight and axially through said flange at angularly spaced locations, the weight and stiffness of said wires being such that said projecting wire ends may provide the substantial mounting support for said combination, one of said windings being seated against said flange, and plastic-bonding means permanently fixing said windings to each other and to said body member.

In combination, a plastic tubular coil-supporting body member comprising a tubular coil-form portion between integral radially outwardly extending flanges at both axial ends, an electrical winding comprising a plurality of turns of relatively heavy and stiff wire deriving concentric support directly from said coil-form portion, the ends of said winding being straight and integrally formed to project axially through one of said flanges and beyond the adjacent axial end of said body member, the weight and stiffness of said wire being such that said projecting wire ends provide the substantial mounting support for said combination, and plastic-bonding means permanently fixing said winding to said body member.

10. In combination, a plastic tubular coil-supporting body member comprising a tubular coil-form portion between integral radially outwardly extending flanges at both axial ends, an electrical winding comprising a plurality of turns of relatively heavy and stiff wire deriving concentric support directly from said coil-form portion, the ends of said winding being straight and integrally formed to project axially through one of said flanges and beyond one axial end of said body member, the weight and stiffness of said wire being such that said projecting Wire ends provide the substantial mounting support for said combination, plastic-bonding means permanently fixing said winding to said body member, and a tubular housing closure member engaging both said flanges and effectively closing the annular space within which said winding is developed.

ll. In combination, a plastic coil-supporting body member comprising a first elongated tubular coilforrn part integrally joined at one axial end to a second radially outward flange part, an electrical winding comprising a plural-turns portion integrally joined at the respective ends thereof to two lead portions, said winding being of relatively heavy and stiff wire and the turns portion deriving concentric support directly from the outer wall of said coilform part, said lead portions being straight and integrally formed to project through and derive alignment support from said flange portion and to project axially beyond said axial end, the weight and stiffness of said wire providing the substantial mounting support for said combination, and plastic-bonding means permanently securing said winding to said body member at the juncture of one of said portions with one of said parts.

References Cited in the file of this patent UNITED STATES PATENTS 1,763,115 Wermine June 10, 1930 2,751,563 Willyard et a1 June 19, 1956 2,836,805 Goldsmith May 27, 1958 2,937,726 Pearlman et al June 3, 1958 FOREIGN PATENTS 592,031 Great Britain Sept. 5, 1947 811,414 France Jan. 14, 1937 

